Method of making pile fabrics

ABSTRACT

A METHOD OF PRODUCING A PILE FABRIC BY NEEDLING A STRUCTURE COMPRISED OF A LAYER OF FIBROUS MATERIAL, A FOUNDATION LAYER AND A STRIPPABLE LAYER, BONDING THE NEEDLED FIBERS IN THE STRUCTURE, AND REMOVING THE STRIPPABLE LAYER.

0.2L 1972 LIN'LUC J. s. OOSTERLYNCK 3,695,962

METHOD OF MAKING FILE FABRICS Filed March 10, 1970 IN VENTORLIN-[0611469055 55mm flaarfeLr/vck 14 TTOE'NEYS United States Patent 01hoe 3,695,962 Patented Oct. 3, 1972 US. Cl. 156-148 12 Claims ABSTRACTOF THE DISCLQSURE A method of producing a pile fabric by needling astructure comprised of a layer of fibrous material, a foundation layerand a strippable layer, bonding the needled fibers in the structure, andremoving the strippable layer.

The present invention relates to novel pile fabrics and to a method forthe production thereof.

Within the last few years there have been numerous proposals concernedwith the manufacture of non-woven pile fabrics, particularly usingneedling operations. For ex ample, a pile fabric has been proposed inwhich fibre tufts are affixed to a fibrous layer and extend normally,therefrom. The fibrous layer may, if desired, have a rubber backinglayer, particular if it is to be used as a carpet material. However, inthese pile fabrics the fibre tufts do not in general provide asuificiently dense pile to ensure that the fibres are suitably resistantto wear. Consequently, as a result of repeated wear the fibre tufts willbe flattened and the fabric will loose its pile effect.

According to a further prior proposal, a fibrous layer is needledthrough a support fabric whereby the needled fibres form tufts extendingfrom the support fabric. The fibre tufts are then fixed in a positionsubstantially normal to the support fabric which is then stripped awayfrom the fibrous layer. The fixing of the fibre tufts may beaccomplished by a heat treatment or by a suitable chemical treatment.However, this method of suffers from the disadvantage that the fibresare often of varying lengths and are often not fixed sufficientlystrongly. Moreover, when the pile fabric is used as a carpet materialthe fibre tufts will be liable to be deformed and torn from the fabricduring use.

In a still further prior proposal a composition comprising fibrouslayers located up and between two woven fabrics is needled using abarbed needle, and one of the said woven fabrics is subsequentlystripped away.

It has also been proposed to prepare pile fabrics by needling a fibrousmaterial through a wax or plastic sheet and subsequently heating thesheet to bond the resulting fibre tufts together.

The present invention is based upon the discovery that novel pilefabrics having good wearing qualities can be produced by a needlingprocess in which a strippable layer of, for example a felt is used toensure that the fibres constituting the pile of the resulting fabric arelocated substantially perpendicular to the fibrous layer thereof, andthe fibres in the pile fabric produced are securely fixed in afoundation layer.

According to one feature of the present invention, there is provided apile fabric comprising a layer of fibrous material and a foundationlayer bonded thereto, wherein fibres from the said layer of fibrousmaterial are needled through the foundation layer and extendsubstantially perpendicularly from the surface of the foundation layerremote from the layer of fibrous material thereby forming a pile.

According to a further feature of the present invention,

there is provided a method of producing pile fabrics which comprises (1)needling a structure comprising (a) a layer of fibrous material: (b) afoundation layer; and (c) a strippable layer adjacent to the saidfoundation layer whereby fibres from the said layer of fibrous materialare needled into the said foundation and strippable layers with asubstantially number of the needled fibres penetrating the saidstrippable layer; (2) subjecting the needled structure to a treatmentserving to set the needled fibres in the foundation layer and bond thesaid layer of fibrous material to the foundation layer; and (3)separating the strippable layer from the foundation layer to form a pilefabric in which the needled fibres extend substantially perpendicularfrom the surface of the foundation layer.

The layer of fibrous material may be composed of any desired natural orsynthetic fibres such as polyamides or acrylic or polypropylene fibres,which may, if desired, be crimped and/or dyed.

It should be noted that while step (1) of the method according to theinvention is always the initial step of the method, steps (2) and (3)are inter-changeable in sequence, although in general it is preferred tocarry out step (2) before step (3).

However, if desired, setting of the needled fibres may be effected inthe absence of any layer. For example the strippable layer may beprovided by brushes mounted on a cylinder e.g. the floating bedplate ofa needling loom, the floating bedplate being in the form of a cylinder(which is generally of a high density and made of metal), the peripheralsurface of which carries a plurality of brushes substantially coveringthe said surface. The height of the brush pile is generally rather morethan the depth to which the needles penetrate during the needlingoperation.

The said foundation and strippable layers are advantageously composed ofa felt material which may, if desired, be reinforced by a cloth or otherwoven material composed for example of synthetic fibres or ribbons suchas polyethylene or polypropylene. The cloth or other woven materialreferred to above may, if desired, be used as the foundation layer inplace of the felt material, particularly when a pile fabric in the formof a velvetlike material is desired. The cloth or similar woven materialused in the foundation layer preferably has a relatively close weave toavoid the spacing of the needled fibres into rows.

Alternatively, the foundation layer employed in the method according tothe invention may comprise a loosewoven cloth which has been needledprior to contacting with the layer of fibrous material.

In order to facilitate removal of the strippable layer from thefoundation layer in the method according to the invention, thestrippable layer is preferably in the form of a pile-like material,particularly a durable close-tufted material, and is advantageouslycomposed of relatively smooth fibres such as polyolefin fibres.Alternatively, the surface of the strippable layer adjacent to thefoundation layer may be impregnated with a suitable lubricant, e.g. asoap emulsion or dilute detergent, to aid the separation of this surfacefrom the foundation layer.

The cloth or similar woven material used in the foundation and/orstrippable layer(s) may, if desired, be replaced by a layer of syntheticplastic or foam material.

The felt materials used as strippable and/or foundation layer(s) in themethod according to the invention may be extensively impregnated, orcoated on one or both sides, thereof, with natural or synthetic laticesor other binding materials. The said felt materials may be the same ordifferent and may differ in their physical and/or chemical nature.Similarly, the foundation layer and the fibrous layer may be of the sameor different colour to provide a pattern on the final pile fabric.

The cloth or similar woven material reinforcing the foundation layer ispreferably located at or near the surface of the said layer adjacent tothe fibrous layer. However, the cloth or similar woven materialreinforcing the strippable layer is preferably located at or near thesurface of the said layer remote from the foundation layer, to avoidundue damage to the reinforcing cloth during the needling operation inthe method according to the invention.

According to the method of the invention, the laminated composition issubjected to a treatment after needling to set the needled fibres in thefoundation layer. This treatment may be effected in any conventionalmanner, for example by applying an adhesive, or potentially adhesive,backing layer to the fibrous layer. This backing layer may be applied,for example, by means of a doctor blade or spreader roller or byspraying the backing composition on to the fibrous layer. Binding agentsor adhesives which may be used in the backing layer include chargenatural or synthetic rubber latex and thermoplastic synthetic resinssuch as soft polyvinyl acetate, polyvinyl chloride plastisols etc. andother binders which are conventionally used in the finishing oftextiles. The binding agent may, if desired, be applied in conjunctionwith a Wetting agent.

After application of the backing layer, the resulting composition may bepassed, for example, through a pair of squeeze-roller to aid thepenetration of the adhesive component of the backing layer into thecomposition to ensure a firm setting of the needled fibres of thecomposition. The needled fibres may be finally set, for example, byheat-treatment of the composition including the backing layer. Thisheat-treatment may be carried out by pass ing the composition through adrying oven, the drying being effected, for example, by infra-redradiation.

In order to provide pile fabric having a sufficiently dense pile, theneedling operation in the method according to the invention may, ifdesired, be repeated until a pile of the desired density is obtained.

In this case, the initially needled laminated composition is preferablyarranged in a closed circuit such that it may periodically be subjectedto a needling operation, the laminated composition conveniently passingaround the bedplate of the loom used for the needling operation. Theserepeated needling operations are generally carried out on the laminatedcomposition before the needled composition is treated to set the fibres,but, if desired, the needled composition may be set temporarily orpermanently after each needling operation. After the final needlingoperation the resultant composition is finally set and the strippablelayer removed. For example, it may be stripped olf from the composition,and the deep needled side of the felt at the base may then be coated orsprayed with a binder used in finishing the textile.

When more than one needling operation is carried out, a fresh layer offibrous material is generally applied to the existing layer or layers offibrous material prior to each needling operation. The fibrous layersmay be the same or different. For example, consecutive layers of fibrousmaterial of different colours and/or fibres may be used to produce adesign on the resulting pile fabrics.

The needle-board pattern for each needling operation is advantageouslyadjusted to ensure that needle patterns are not visible in the pile ofthe fabrics of the invention. This may be effected by suitably adjustingthe rate of advance per stroke for each needling operation.

The height of pile in the fabrics produced according to the invention isgenerally at least of the order of 4-12 mm. Relief effects on theresulting pile fabrics may be obtained by varying the barb penetrationof the fibrous layer into the strippable layer.

With regard to the needling operation, the term barb penetration is usedherein to indicate the depth of the first barb of the needles, measuredunder the surface of the bedplate of the needle loom. The barbpenetration in the method according to the invention preferably does notexceed the combined thickness of the strippable and foundation layers,in order to avoid difficulties in separating the former layer.

The bedplate in the needling loom employed in the method according tothe invention may conveniently be a grooved bedplate containing rows ofgrooves, as used for example in the burr tufting process. Thepositioning of the needles in the needleboard of the loom will dependupon the location of the rows of grooves in the bedplate.

The strippable layer, which is removed, e.g. stripped off, from theneedled composition in the method according to the invention, maygenerally be used again in a subsequent operation as the provisional orfoundation layer, for example in a continuous process wherein theprovisional layer is run in a closed loop, and is thereby used in aplurality of needling operations. After removal of the provisionallayer, the pile fabric produced may be cut and trimmed, and wound on aroller for storage etc.

According to a further feature of the present invention there isprovided a modification of the method according to the invention whichcomprises (1) needling a structure comprising (a) a layer of pre-needledfelt or a loose- Woven cloth and (b) a strippable layer, whereby fibresfrom the felt or loose-woven cloth are needled into the strippablelayer; (2) subjecting the needled composition to a treatment serving toset the needled fibres in the firstmentioned layer; and (3) separatingthe strippable layer from the first-mentioned layer to form a pilefabric.

Alternatively, according to a further modification of the methodaccording to the invention, the said fibrous layer and foundation layermay be replaced by a conventional layer of a threaded material, and themethod according to the invention carried out using the resultingcomposition. The threads of the threaded material are needled or tuftedthrough a foundation felt or cloth and into the strippable layer, andthen coated, the strippable layer being subsequently removed, to give aloop-surfaced cloth.

When the pile fabrics according to the invention are intended for use ascarpet materials they are preferably provided with one or more furtherwear layers of a relatively heavy backing material, e.g. rubber, toprovide a firm and robust base for the material.

In general, the pile fabrics according to the invention may be used ascarpet materials or as wall covering, upholstery or furnishing fabrics.These fabrics have a soft resilient pile and yet are reasonablyresistant to wear. When materials of relatively low density are used,the re sulting pile fabric will resemble a velvet-like material.

For a better understanding of the invention, certain preferredembodiments of the method according to the invention will be describedwith reference to the accompanying drawings, wherein:

FIGS. 1 and 4 to 6 illustrate preferred embodiments of the methodaccording to the invention,

FIG. 2 is an elevation of a pile fabric according to the invention, and

FIG. 3 is an elevation of a deep needled felt used in the methodillustrated in FIG. 4.

With regard to the method illustrated in FIG. 1, a foundation layer 2.reinforced by a cloth 4, and a strippable layer 1 reinforced by a cloth3, are provided with a layer of fibrous material 5. The laminatedcomposition is needle in a needle loom 6, and a back coating 7subsequently applied to the fibrous layer of the needled composition.The back coating is then dried by passing the composition through adrying oven 8 to fix the needled fibres, and the provisional layer isstripped off, and wound on a reel 9, while the resulting pile fabric 11is wound on a separate reel 10 for storage. FIG. 2 illustrated anelevation of the pile fabric obtained. With regard to FIG. 4, a deepneedled felt 12 is first prepared as illustrated in FIG. 3 by needling afibrous layer 13 having a reinforcing cloth 14, and is then brought intocontact with a strippable layer 15 and the laminated composition needledin a needle loom 16. The method is then carried out as illustrated inFIG. 1.

With regard to FIG. 5, a layer of cloth 18 and a fine felt strippablelayer 19 are provided with a layer of fibrous material 17 and thelaminated composition needled in a needle loom. The needled compositionis then coated, by means of a spray 20, with a back coating, and passedthrough two squeeze-rollers 21. The method is subsequently carried outas illustrated in FIG. 1.

With regard to FIG. 6, the method illustrated in FIG. 1 may be-carriedout using a continuous length of felt 23 as the strippable layer.

The following examples illustrate the invention.

EXAMPLE 1 A fibrous layer composed of 22-dtex 60-mm. crimped fibres of100-g./m. dyed virgin polyamide 66- is deposited, by means of a cardingapparatus and then a Camel Back folder, upon an endless apron upon whichlie two needled felts composed of 17-dtex ca.-80 mm. crimped fibres of300-g./m. reclaimed nylon; these felts, which may be dyed to the same ora slightly different colour to firstmentioned layer, are reinforced withpre-stabilised 80-g./ m? polypropylene cloth, and bonded with 710% of aself cross-linking resilient acrylic latex. The felt layer adjacent tothe apron is hereinafter referred to as the strippable felt layer whilethe felt layer adjacent to the fibrous layer is referred to as thefoundation felt layer. The strippable felt layer is deposited on theapron with its reinforcing cloth adjacent to the apron, while thefoundation felt layer is deposited upon the said strippable layer withits reinforcing cloth upwards.

This layer composition is subjected to a needling operation in aclassical needle loom, with a barb penetration of 2 mm., with 32 normalgauge close barb-needles and containing 2,400 needles per metre, theadvance being 3.3 mm., whereby the composition receives 72 punches percm.

The needled laminated compoistion is subjected to second and thirdneedling operations after the application of second and third fibrouslayers, respectively, onto the first mentioned fibrous layer.

The three fibrous layers totalling 300 g./m. contain fibres projectingthrough the foundation layer and into the strippable felt layer, andorientated substantially perpendicular to the fibrous layers. Thereinforced laminated composition is coated, on the outer fibrous layer,with a clay-loaded vulcanised natural latex on a doctor-blade coatingmachine to form a back coating having a dry weight of 750 g./m.Penetration of the latex into the compoistion during coating iscontrolled, to ensure that the latex penetrates as far as thereinforcing cloth of the foundation felt layer and, if desired, slightlyin excess thereof. The coating is dried and vulcanised to ensure a firmbonding of the base of all the fibre tufts, an improved bonding of thefoundation felt layer to its reinforcing cloth and to maintain theneedled fibres substantially perpendicular to the reinforcing cloth ofthe foundation felt layer.

If desired, a foamed natural latex composition is applied in a quantityof 600 g./m. on the back coating and engraved as a walfel, thisfinishing imparting an anti-slip effect to the carpet.

To ensure easy removal of the strippable felt layer after applying theback coating, a soap solution is spread uniformly upon the surface ofthe strippable felt layer.

After leaving for 2-3 min. the strippable felt layer is readily removed,between two rollers, from the foundation felt layer leaving a densematerial resembling Wilton carpet. While the strippable layer is woundon a reel, the

6 carpet material is trimmed and wound on a reel. This carpet materialhas a total weight of 2030 g./m. comprising 300 g./m. of fibrous tufts 6mm. in height, a foundation layer of 380 g./m.-"', 3 mm. in depth, and abacking weighing 1350- g./m.

EXAMPLE 2 A deep needled felt 12 shown in FIG. 3, composed of a layer,weighing 400 g./m. of dyed reclaimed slightly crimped acrylic fibres of15 denieri mm. is needled with a 32 gauge normal regular barb needleboard on to a polypropylene cloth 14 of 80 g./m. with a barb-penetrationof 9 mm. The needled compoistion is then reversed on a strippable feltlayer 15 as described in Example 1 and subjected to a needling operation16 with the same setting as described in Example 1 except that theadvance per stroke is reduced to 2 mm. The laminated compositionobtained is coated with a pure acrylic emulsion in a quantitycorresponding to 200 g./m. After drying, and removal of the provisionalfelt layer, the edges of the acrylic pile fabric obtained are trimmed.This pile fabric is soft and light (680 g./m. and may for example beused as a chair-furnishing material. The strippable felt layer may beused again for the same purpose in a subsequent operation.

EXAMPLE 3 The procedure described in Example 2 is repeated, except thata layer of dyed garnetted slightly crimped polyamide 6 fibres ofl7-dtex, nearly 80 mm. in length, is used in place of the layer ofacrylic fibres. After the first needling operation a further a layer of2.00 g./m. of the same fibres is deposited upon the compositionobtained, and needled in a similar manner to that described in Example2.. A back coating of loaded butadienestyrene latex weighing 1200 g./m.when dry is applied on to the last-needled layer followed by theapplication of a jute cloth weighing 255 g./m. to impart dimensionalstability to the pile fabric.

The strippable felt layer is then stripped and wound on a reel to beused again if necessary. The carpet material is then trimmed. If thegarnetted fibres used are not of regular length, the pile fabric canadvantageously be sheared.

EXAMPLE 4 A web 17 shown in FIG. 5, composed of IO-dtex dyed acrylicstaple fibres, 40 mm. in length, and weighing 80 g./m. produced by anairlaid dofling card, is applied on to a dyed twisted cotton cloth 18 of80 g./m. resting on a strippable acrylic-bonded felt layer 19 composedof multi-coloured IZ-denier polypropylene crimped fibres, 80 mm. inlength and weighing 300 g./m. needled upon a polyethylene sheet of 0.07mm. thickness. The composition is then needled with 36-gauge normalclose barb needles with an advance of 4 mm. and a barb penetration of 1mm. The needled surface of the composition is then sprayed with a softcross-linking acrylic binder (in an amount corresponding to 30 g./m.containing a wetting agent, and the sprayed composition is passedbetween two squeeze-rolls 21 and then dried by infra-red heating. Afurther web of the same fibre is deposited on the coated surface of thecomposition and needled again with the same setting but with a differentadvance to avoid needleboard patterns.

A further spraying treatment with the same quantity of the sprayingcomposition is applied, dried and cured as described above. Thestrippable felt layer 19 is stripped off and, if desired, re-used forthe same purpose in a subsequent operation. The pile fabric obtained istrimmed and is in the form of a velvet-like material which may be usedas a wall covering, furnishing or upholstery material.

7 I claim: 1. A method of producing pile fabrics which comprises thesteps of:

needling a composite structure comprising (a) a layer of fibrousmaterial and (b) a strippable layer of felt whereby fibers from thelayer of fibrous material are needled into the strippable layer whichserves to locate the needled fibers in positions substantiallyperpendicular to the plane of the layer of fibrous material; the saidlayer of fibrous material being selected from a layer of fibrousmaterial supported on a foundation layer situated between the layer offibrous material and the strippable layer, and, a layer of materialselected from the group consisting of a pre-needled felt and aloose-woven cloth, said material being sufiiciently self-supporting forneedling; and the said strippable layer having a thickness such thatduring needling the barb penetration of the needles does not exceed thethickness of the composite structure; bonding the needled fibers in thestructure; and separating the strippable layer from the structure toprovide a pile fabric wherein the pile is formed by the needled fibersextending perpendicularly to the plane of the layer of fibrous material.2. A method according to claim 1 wherein the strippable layer comprisesa felt which is reinforced by a woven material located adjacent to thesurface of the strippable layer remote from the layer of fibrousmaterial. 3. A method according to claim 1 wherein the strip pable layeris provided by needled felt.

4. A method according to claim 1 wherein the layer of fibrous materialis supported on a foundation layer.

5. A method according to claim 1 wherein the composite structureincludes a foundation layer composed of a felt material.

6. A method according to claim 5 wherein the felt 8 material isreinforced by a woven material located adjacent to the layer of fibrousmaterial.

7. A method according to claim 1 wherein the foundation layer iscomposed of a woven material.

8. A method according to claim 1 wherein the bonding of the needledfibers is effected by applying an adhesive backing layer to the layer offibrous material.

9. A method according to claim 1 wherein after said needling step butbefore said step of separating said strippable layer, the structure issubjected to at least one additional needling operation, each suchadditional operation comprising contacting the side of the structureremote from the pile with a further layer of fibrous material andneedling the resulting structure to increase the density of the pile.

I10. A method according to claim 9 wherein the additional needlingoperation is effected after said needling step but before said bondingstep.

'11. A method according to claim '9 wherein the additional needling stepis effected after bonding the needled fibers from said first needlingstep.

12. A method according to claim 1 wherein the height of the pile in theresultant pile fibric is 4-12 mm.

References Cited UNITED STATES PATENTS 3,010,180 11/1961 Hofiiman156-148 X 3,348,993 10/1967 Sissons 156-148 X 3,230,134 1/1966 Studer a156-435 X 3,347,736 10/ 1967 Sissons 156-148 X 2,831,525 4/1958 Cole156-435 X CARL D. QUARFORTH, Primary Examiner G. G. SOLYST, AssistantExaminer US. Cl. X.R.

